Search Documents

By B. Crane, S. Schwartz

"IntroductionThe Cape Breton Development Corporation (CBDC) located in Cape Breton, Nova Scotia, in eastern Canada, was established in 1967. Its mandate at that time was to facilitate a phased downsizing of the coal industry and developing viable replacement industries. The oil crisis in the early 1970s changed CBDC’s mandate and focus was modified to increase coal production to support Nova Scotia Power Commission’s “off oil” policy for their power generators. In the late 1980s the mandate to develop viable replacement industries was eliminated and CBDC became primarily a coal mining company. CBDC presently operates two underground coal mines, Phalen Colliery and Prince Colliery, using a retreat longwall method of mining. Both mines operate beneath the Atlantic Ocean. CBDC also operates associated infrastructure — central workshops, a railroad, coal preparation plant, and international pier. The Need For Substantial ChangeOver the last few years, CBDC has been facing some challenging issues, including improving labour management relations and achieving financial self-sufficiency and profitability. Recent achievements with regard to human resource issues, especially in the areas of collective bargaining, absenteeism, and attendance, show noticeable improvements. All participants should be commended for successfully concluding the collective bargaining process with all four CBDC unions, CUPE; CAW; IAM&AW; and UMWA. However, although these changes are encouraging, even critical in the short term, they are not sufficient to ensure the long-term viability of the company. Market ForcesShort- and long-term financial realities are drawing the need for further substantive changes. The corporation has a mandate to achieve financial self-sufficiency by the year 1999. This goal can only be achieved through a combination of cost reductions and productivity gains, specifically, a reduction in the workforce of 658 and an increase in production of 800 000 tonnes annually. This increase in productivity requires CBDC to re-think the way it does things.In the longer term, CBDC faces even greater challenges. The energy market is becoming more competitive. The electrical utilities across Canada are anticipating deregulation and are positioning themselves for the resultant competition. As primary fuel supplier to Nova Scotia Power Inc. (NSPI), the corporation will have to become ever more competitive to stay in business."

Jan 1, 1997

By Ralph Harris, Xia Qi, Frank Komsic

"Gold cyanidation kinetics which are often limited in commercial operations by the rate of oxygen dissolution from gas bubbles into the slurry, are discussed. Emerging technologies for improving the rate of oxygen dissolution are compared and the gas efficiency, energy use and operating performance of inverted cones and a device based on a jet diffuser are examined. The effect of solids loading is also reviewed and a relationship between operating parameters and the kilograms oxygen dissolved per kilowatt-hour is presented.Inverted cones are shown to create slurry settling problems at high gas flow rates and surface tension lowering agents are shown not to greatly improve the overall rates of oxygen dissolution.The novel jet diffuser technology operates at a range of gas to liquid ratios that improves its energy use over conventional technology and the performance of a number of designs are discussed.Gas efficiencies as high as 35% were observed with the novel diffusers at 40 cm diffuser immersion and are expected to increase at greater immersions. Energy use of 1.8 kg 02 I kWh were estimated for prototype full size diffusers operating at 100 cm immersion. Energy use of 3.S kg 02 /kWh is conservatively expected at 600 cm immersion.IntroductionGold ExtractionGold that can not be recovered by gravity separation can be recovered by either the Merrill-Crow process or the newer carbon in pulp (CIP) or carbon in leach (CIL) processes 1. Reductions in operating costs and improvements in gold recovery are central mill operating strategies. The present paper examines the potential for improvement that can be achieved in the gold cyanidation step of gold recovery. This paper introduces a number of emerging technologies and provides a basis for comparison of the performance. It shows that the basis for comparison of a particular technology depends on the type of gold extraction circuit employed and the type of reactants employed."

Jan 1, 1996

By Daniel D. M. Adams

Over the last 100 years industry in general has been trying to advance the ability to maintain systems through management processes. Mining has looked to utilize onboard data systems in our mobile mining fleets to compliment these processes. Combining the two concepts build the concept that Rio Tinto refers to as asset health. These programs can generate a cost shift between $20,000 and $100,000 per piece of equipment annually. Even with the documented savings many operations struggle to justify the systems, why?

May 1, 2011

By S. Harshaw, C. Doyle, A. E. M. Warner, D. Stremlaw

"In the Utility Nickel furnaces, the hearth and sidewalls are lined with high-Al2O3 bricks. During charging and thermal cycling (more so as the linings on these reverberatory furnaces age), pieces of brick spall or abrade from the refractory and collect on the top of the bath. These pieces are removed using a non-corrosive slag toward the end of the heat when the bath temperature is ~1600°C.This benign liquid can be generated by two methods. First and most obvious, suitable ingredients can be pre-mixed so that the flux (flux A) is isochemical with the non-corrosive slag. All that is needed to produce this targetted slag is heat. Second, in other proportions (flux B), the pre-mixed ingredients generate a corrosive slag that melts completely at -1200 °C and corrodes some but not all of the brick particles on the bath surface. As the reaction progresses, the slag changes composition eventually attaining the targetted benign composition. Using this option, additions are monitored to avoid overfluxing. In both cases, the generated slag/brick mixture can then be rabbled from the furnace. This practice has been successfully used for over two years and has been a factor in extending Utility Nickel furnace life to its current levels (about25% increase)."

Jan 1, 1993

By Michel Lefebvre, André Piché

Every organization performing R&D is faced with the challenge of introducing new technologies to its operations. Difficulties must be overcome if companies are to realize the benefits anticipated from such developments. This paper outlines the difficulties encountered in transferring to operations various technologies developed at the Mining and Exploration Division of the Noranda Technology Centre. The approach used in the selection of a privileged partner for the technology transfer, the criteria motivating the choice and the process followed to establish the partnership are presented.

Jan 1, 1997

OVERVIEW OF PRESENTATION ? What is LMI ? Who uses LMI and how? ? Value of LMI to the Mining Industry ? Mining Industry Workforce Information Network (MIWIN) ? The Challenge: Forecasting the future in uncertain times ? Results: Hiring requirements in the next decade ? Results: Occupational information ? Next steps

May 1, 2009

By B. V. Knelson

"GENTLEMEN:This paper will deal with centrifugal separation - theory and practical, and since the Knelson Concentrator is the only centrifugal concentrator with a properly fluidized bed, this paper will cover the Knelson Concentrator and its technical and structural advances over the last five years. As I am the person with the most experience in this line, I guess I am some kind of an expert; what kind I’m not sure, but some kind.This type of concentrator truly was developed because I’m lazy and I constantly look for easier ways to do things. My experience in the mining industry was very limited but I did realize in looking at placer operations, which is the application where I spring from, that it was tremendously labour intensive and my first reaction that ""my god, there must be some method or way-of handling product in a more efficient (and you can read that as being able to quickly recover very fine particle gold) way than was being shown at that time"". So, the Knelson Concentrator was born - about 6 or 7 years later. Our first attempt was a cone with about the same degree of slope as our present machine and since we had no knowledge of vibration dampening and centrifugal forces at that point, it was just an idea that this should work.Our first run was one of twenty minute duration. We did make that first machine variable speed by a mechanical belt system and we found that at about 240 rpms we were virtually shaking the gravel plant apart that we were attached to. So the first run was twenty minutes and back to the drawing board. However, that first run produced a concentrate so superior to anything we had seen previously, that we knew without any question, we were definately and accurately on the right track."

Jan 1, 1985

By T. A. Grammatikopoulos, B. Vasily, A. H. Clark

"The St. Lawrence deposit is a large wollastonite skarn (ca. 9 Mt @ 41.3% wollastonite) adjoining the gabbroic-to-syenitic Leo Lake pluton in the granulite facies Frontenac Terrane of the Grenvillian Central Metasedimentary Belt. It occurs within a horseshoeshaped horizon of quartzite, open to the east. The skarn extends over 1.2 km2, and comprises wollastonite-dominant, wollastonite-clinopyroxene, and diverse quartz-feldspar-sulphide (-titanite) layers, interbanded with, and strongly folded within, the quartzite. As in the world-class wollastonite deposits of the Willsboro district, New York, no carbonate protolith is preserved, and calcite is a negligible constituent of the mineralized zones. Wollastonite development is nonetheless ascribed to metasomatism of a metacarbonate unit by magmatogene, silica-rich, CO2-poor (XCO2 < 0.05) fluids, at P = 350 MPa and ca. 560°C, or, alternatively, 550 MPa and ca. 630°C.Several high-grade zones, averaging >40% but locally exceeding 80%, of translucent, white, tabular wollastonite grains, with lengths of 0.2 cm to 5 cm, have been delimited by drilling. Preliminary beneficiation studies yield high aspect-ratio and high-purity (low Fe and Mn) concentrates.St. Lawrence compares favourably to other known prospects and operating wollastonite deposits: having good chemical and physical properties, low iron content, and high aspect ratios (>20:1). In addition, the deposit has a favourable size and location, and will benefit from a low Canadian dollar. Canada currently has no wollastonite production."

Jan 1, 2003

By Chris Brown

"The Island Copper plant was designed and built by Fluor Utah Ltd, in conjunction with Utah design staff, Originally designed to treat 33,000 tons/day (t/d) of ore, the current average milling capability is 38,000 t/d (Nov'74). The first of six semi-autogenous grinding lines was brought on line in October 1971, startup of the remainder being governed by equipment delivery schedules.The summer of 1973 saw the start-up of an additional three ball mills, and attainment of the present production level. The current process flowsheet is shown in simplified form.CRUSHINGThe crushing circuit is relatively simple, comprising single stage crushing of the ore followed by screening to fine and coarse fractions.The crusher is a 54 x 74in. Allis Chalmers Superior Gyratory with a setting of 9-lOin., driven by a 500-hp motor. Trucks dump on three sides of a rectangular dump pocket. An 84in. x 20ft. link belt apron feeder draws crushed ore from a 250-ton surge bin below the crusher, discharging onto a 72in. wide inclined steel cord conveyor belt. A fixed splitter box at the conveyor discharge separates feed to two parallel Jeffreys 6 x 20ft. vibrating grizzlies for screening into +4in. and -4in. fractions. The fractions are collected on short reversible conveyors which feed the coarse and fine ore stacker conveyors. Trippers distribute ore to outside stockpiles adjacent to, and above, the concentrator grinding 'floor."

Jan 1, 1975

By Jayne Somers

Methane (CH4) is a potent greenhouse gas, accounting for 15 percent of all global greenhouse gas emissions in 2005. Since methane has a much shorter atmospheric lifetime than carbon dioxide (CO2), reducing methane emissions can achieve considerable climate benefits over the next 25 years. Coal seams often contain significant quantities of methane and CH4 released to the atmosphere from gassy mines during coal extraction is a major source of greenhouse gas emissions. Methane (CH4) emissions from coal mining activities constitute approximately 6% of total global human-related methane emissions. Coal mines around the world have recognized that methane is a clean energy resource that can be captured and used productively. Coal mine methane (CMM) is currently utilized for power generation, natural gas pipeline injection, vehicle fuel, industrial process feed stocks, on-site mine boilers, mine heating, and home heating distribution systems. Upgrading mine degasification systems can often improve gas quality and create favorable project economics. The United States has been a leader in coal mine methane (CMM) recovery and use since the 1990?s. There are now 15 projects at active underground mines in the U.S., as well as 26 abandoned mine methane projects. Recovery and use projects at active underground U.S. mines reduced methane emissions by approximately 49 Billion cubic feet in 2010. In an exciting new development, a ventilation air methane (VAM) mitigation project at the CONSOL McElroy mine in West Virginia was installed by Verdeo. Operational since September 2012, this is the first commercial-scale VAM project in the U.S. and the project will reduce methane emissions by an estimated 920 MMCF/yr. As part of the U.S. Greenhouse Gas Reporting Program, actual data on methane emissions from underground coal mines was collected for the first time in 2011 and reported to U.S. EPA in September 2012. The data collected will help inform stakeholders, particularly the underground coal mining industry, of CMM emission sources on public and private lands. The detailed data will also shed light on the specific sources of methane from active underground coal mines and highlight project opportunities for the U.S. coal industry. The paper will cover U.S. coal mine methane emissions, U.S. CMM utilization and destruction projects, Federal policies and State incentives for CMM capture and utilization. 2011 CMM data from the U.S. Greenhouse Gas Reporting Program Subpart FF will be analyzed and compared with previous U.S. Greenhouse Gas Inventory estimates. Other developments, including the voluntary carbon market, will be discussed.

Aug 1, 2013

By F. W. Brackebusch, R. O. Sack

"A method for determining the fineness of Au in electrum from the composition of fahlore coexisting with pyrite and chalcopyrite is presented. This method is based on previously published experimental brackets and activitycomposition models for electrum and fahlore, and it is potentially useful for defining temperatures of hydrothermal mineralization and retrograde evolution of precious metals deposits. The authors demonstrate that it successfully predicts compositions of electrum reported for this assemblage in the literature and illustrate its application for three gold-quartz vein deposits from the Coeur d’Alene mining district, Idaho, that are prospects of the New Jersey Mining Company, the Coleman vein, High-Grade prospect, and Silver Strand mine. Temperatures calculated from average electrum compositions estimated from gravity concentrates (molar Au/(Au+Ag) = 0.76-0.39) and from microprobe analyses of the fahlores (molar Ag/(Ag+Cu) = 0.039 ± 0.004, Zn/(Zn+Fe) = 0.57 ± 0.03, As/(As+Sb) = 0.23 ± 0.02) from the Coleman vein indicate that the electrums underwent retrograde re-equilibration to temperatures between about 80°C and 240°C, roughly 80°C below the temperature of hydrothermal mineralization and 10°C to 40°C above the temperature inferred for retrograde equilibration of Fe and Zn between sphalerite and fahlore. Fahlores from the High-Grade prospect [molar Ag/(Ag+Cu) = 0.009 ± 0.004, Zn/(Zn+Fe) = 0.55 ± 0.11, and As/(As+Sb) = 0.04 ± 0.03] and Silver Strand mineralized zone [molar Ag/(Ag+Cu) = 0.10 ± 0.04, Zn/(Zn+Fe) = 0.63 ± 0.02, and As/(As+Sb) = 0.06 ± 0.02] exhibit strong core to rim depletions in Ag due to retrograde operation of the reaction1/10Cu10Fe2Sb4S13 + Ag + FeS2 =Cu-fahlore electrum pyriteCuFeS2 + 1/10Ag10Fe2Sb4S13chalcopyrite Ag-fahlorewhich proceeds to the left with decreasing temperature. Electrum inclusions in arsenopyrite from the High-Grade prospect [molar Au/(Au+Ag) = 0.90 ± 0.02] define a minimum bound on the temperature of hydrothermal mineralization of 273°C, and the temperatureelectrum composition curve constructed for the most Ag-rich fahlore in the Silver Strand mine indicates that the fineness of its electrum is significantly less than in the other deposits."

Jan 1, 2004

By G. C. McKerrow

"Mr. G.C. McKerrow, Assistant Manager of Noranda Mines and formerly Smelter Superintendent attended the meeting to answer questions as to why smelters imposed penalties for too much zinc in a copper concentrate or too much copper in a zinc concentrate, etc.D.W. Bridges -Mattagami Lake MinesWhat limits do you set on zinc and lead in a copper concentrate?G.C. McKerrow - At Noranda, we allow 5% zinc free and charge 25 cents for every unit above that. For lead, it is 1% free and 25 cents per unit above that. Lead is a much more harmful impurity than zinc because it tends to recycle more in the smelter circuit and creates a greater health hazard in the plant.E. Thornton - Sullivan GroupWHat harm does fluorine do in the smelting process?G.C. McKerrow - Fluorine usually does not occur in harmful concentrations in non-ferrous smelters. Fluorides are present in exhaust gases in the aluminum and phosphate industries. If these fumes escape into the atmosphere, they may settle out on forage grasses in concentrations that are harmful to livestock.Thorton - Sullivan GroupI have asked this question other places and have been told that it is hard on brick linings and causes gold and silver to be lost up the stack.G.C. McKerrow - Almost any volatile constituent in a smelter charge will aid in carrying other metal values. To this extent it may be harmful.E. Thornton - Sullivan GroupMr. Tait mentioned before a smelter where they have a copper-tin ore and they pay for copper, tin, bismuth and silver but object strongly to indium in the concentrate. Why would this be?G.G. McKerrow - 1 can't see why indium would be a serious impurity. It does tend to concentrate in flu dusts and if you get enough of it you can recover it and sell it but I have never heard of anyone putting a penalty on it.Question - I once ran into a small copper mine in Peru that had cadmium in the copper concentrate but no zinc. The copper smelter charged a penalty for the cadmium. Why would this be?"

Jan 1, 1971

By P. G. Claridge, R. A. Tenbergen

"Pipe Open Pit ore is delivered by rail to the Thompson Mill at a rate of 34,000 tons per week. Ore is milled at a rate of 220 tons per hour.Characteristics of the serpentinised peridotite host rock are such that significant deviations from hitherto experienced milling practice became a necessity because of coagulation of the gangue upon cominution.Extensive development work was done in the grinding and classification circuits to better understand the ore characteristics and optimize operating parameters and the use of available equipment. This work ultimately resulted in the change from 30 to 20-inch diameter cyclones.Coagulation of the ore slurry and the characterstics of the sulfide minerals necessitated an ""unconventional approach"" in processing as compared with the beneficiation of Thompson Mine ore.Recent changes in ore characteristics led to testing of antistatic agents to reduce tailing losses."

Jan 1, 1975

By P. V. Avotins, I. Djurkovic, D. R. Nagaraj, M. Grunjic, A. Day

"As part of a major reconstruction and expansion of the Majdanpek Copper Mine, an investigation and optimization of the flotation collector regime was undertaken. The flotation response of the major minerals to various reagents and the effect of pulp chemistry was studied from both a fundamental and practical point of view. These studies led to plant trials and the eventual adoption of a modified collector suite which improved both copper and gold recoveries.INTRODUCTIONThe Majdanpek Copper Mine processes 40,000 tons per day of ore containing about 0.43% cu. In addition to copper, the ore also contains recoverable quantities of molybdenite and gold. The mine has been in operation since 1961 and is the largest in Yugoslavia. It is currently undergoing major reconstruction and expansion. The flowsheet of the Majdanpek concentrator is shown on Figure 1.The ore body is variable in composition and changes in mill feed require proper control of operating variables to achieve the optimum metallurgical results. A detailed study including grindability, flotation response, and solid-liquid separation was carried out on several samples of the ore. Flotation response and the choice of reagent chemistry were found to be very important in achieving the highest recoveries of metal values. An automatic reagent control scheme insured that optimum dosages were used in the plant.The flotation collectors used at the present time include sodium isopropyl xanthate (SIPX), AERO 3302 Promoter and AERO 5415 Promoter. The addition of AERO 5415 to the reagent suite is a recent development and was based on the favorable results obtained in the extensive laboratory testing program conducted to establish the optimum reagent combination and dosages. Subsequent plant tests confirmed that AERO 5415 provided significant improvements in copper and gold recoveries. A description of the mineralogy of the Majdanpek ore and details of laboratory and plant metallurgical data are given in this paper. The chemistry of AERO 5415 Promoter and its interaction with minerals relevant to Majdanpek ore are also discussed."

Jan 1, 1992

By R. N. Murarka

"Hydrocyclone modelling and selection procedure is illustrated. Computerized procedure for hydrocyclone cut size determination for grinding and non-grinding applications is described.A standard procedure for evaluating operating hydrocyclones is described in detail. Many case studies are illustrated comparing actual plant performance with the computer simulation output in terms of overflow product size distributions.INTRODUCTION Cyclones are widely used for applications such as: close circuit grinding, backfill, tailings and dewatering. Normally, cyclones are used for very fine separations where screens are not suitable or too expensive. Figure 1 shows the separation size range of various classifying devices. Cyclones are popular because of their low capital and operating cost. Cyclone selection procedure for different applications depends on the amount of information available on the cyclone feed slurry characteristics. Closed circuit grinding applications will be discussed in detail in this paper. The Cut Size:The size of the material in the feed which reports 50% to each product stream (i.e. underflow and overflow), after correcting for the feed solids by-passing with the underflow liquid, is termed the cut size or ""d50c"". This is often used as the criterion and the basis for cyclone design.When the corrected recovery to underflow of each mesh size in the feed is plotted against the geometric mean size in microns on a log scale, the micron size corresponding to 50% recovery is the d50c size."

Jan 1, 1992

By V. I. Lakshmanan, D. A. Mackie

"1. INTRODUCTIONIn the past two decades, low-grade gold and silver ore bodies in the United States have been exploited by heap leaching, primarily with sodium cyanide solutions. This method has proven to be a viable alternative to conventional milling due to its low capital and operating costs. Successes have been made, particularly in Nevada, where ores are well oxidized and the climate is conducive to this method. in recent years, heap leaching has been tried in northern latitudes with some success, however, in using this method, operators face more severe limitations than do their neighbours to the south.This paper evaluates the limitations of heap leaching with particular emphasis on northern climates and introduces an alternative method to recover precious metal values in a continuous vat. This proprietory technology, known as the Mackie Vat Leaching Jig, shows promise, with improved gold recovery and potential to operate in cold climates.2. WHAT ARE THE LIMITATIONS TO HEAP LEACHING?Heap leaching of non-refractory ores is subject to the following limitations:1. Minimum amount of free gold and nuggets in the ore.?. Minerology of the ore--accessibility of gold to lixiviant.3. Minimum particle size and size distribution of crushed product to allow percolation of lixiviant through the heap.4. Minimum amount of clays or clay-like slimes that can cause coating of ore particles and channelling of lixiviant.5. Minimum strength of ore particles or agglomerations to allow economic height of heaps to be built.6. Amount and suitability of real estate.7. Amount and type of precipitation.8. Ambient temperatures.9. Possible poorer lixiviant diffusion.10. Possible lower oxygen content in dissolved cyanide solution with higher heaps, particularly with ice and snow cover."

Jan 1, 1989

By Andy Lemay

Vale (previously known as CVRD) is: ? The second-largest mining company by market capitalization (NYSE:RIO) ? Headquartered in Brazil ? Global workforce of over 100,000 employees including outsourced workers. Vale Inco Limited is a wholly?owned subsidiary of Vale Vale Inco Limited ? is based in Toronto, Ontario Canada: ? Operations and Projects in 20 countries ? Marketing Network extending to 40 countries ? Over 12,000 employees worldwide ? Last years sales of US $8 Billion

May 1, 2008

By T. Salman

Most authorities agree that the dissolution of gold from an ore takes place according to the Elsner equation first stated in 1846. The main requirements for the dissolution reaction to proceed are:(1) that the gold be clean.(2) that the gold be exposed to the solution.(3) that the cyanide solution be active, i.e., not over loaded with impurities which could retard or inhibit the reaction.(4) that an adequate supply of oxygen be available (from air).When the above conditions are met, cyanidation becomes basically a mechanical operation.Minerals such as quartz, calcium carbonate are relatively inert to cyanide though they may give rise to mechanical troubles. Most ores present an assortment of chemical problems, depending upon the constituent present, which react to the solution to varying degrees. It should be borne in mind that minerals which are disturbing to the operation, though present in small amounts, usually exceed the weight of the gold by several hundred times. In addition, the application of flotation and other forms of concentration to gold ores, previous to cyanidation, concentrates not only the gold, but also the other heavy minerals and these complicate the chemistry of the process.

Jan 1, 1975

By H. U. Ross

"INTRODUCTION Extensive studies have been carried on pure gold to determine the various factors that affect its dissolution in alkaline cyanide solutions. With the extension of milling to refractory ores more intensive investigations on the effect of impurities in the ore on the dissolution kinetics are needed. The present work describes experiments carried on refractory flotation tailings with the object to determine how the recovery of gold could be increased. The effect of arsenic and antimony in the ore and the excessive use of lime are discussed. Control of cyanide losses is also dealt with.MECHANISM OF THE GOLD DISSOLUTION REACTION In aqueous cyanide solutions, gold is believed to be dissolved by one of the following reactions:4Au + 8NaCN + O2 + 2H20 = 4NaAu (CN)2 + 4NaOH (1)2Au + 4NaCN + 2 + 2H20 = 2NaAu (CN)2 + 2NaOH + H202 (2)2Au + 4NaCN + H202 = 2NaAu (CN)2 + 2NaOH (3) The first of these, known as the Elsner Equation is supported by )4 3,2,1(several authors while others(5,6) support reactions 2 and 3 known as the Bodlander Equations. According to Habashi(7), the overall reaction for the dissolution process is as shown in equation 2. Most of the workers agree that hydrogen peroxide is produced in the course of the reaction."

Jan 1, 1973

By R. A. Bergman, C. A. Pickles, J. M. Toguri

"Black calcium cyanide is utilized mainly as a reagent for gold extraction. It is produced by reacting calcium cyanamide, sodium chloride and calcium carbide at temperatures in the range of 1200°C to 1400°C in a smothered arc furnace. The equivalent sodium cyanide content of the product is in the range of 45% to 50% and the calcium cyanamide conversion efficiency is in the range of 90% to 95%. Since black cyanide contains impurities such as salt and lime and also because the conversion efficiencies are below 100%, the product contains unwanted materials which significantly increase the shipping costs.The impurity content of the raw materials can not be lowered without increasing their cost and/or the processes to produce them, and therefore the present research was focussed on studying those factors which affect the cyanide grade. The major variables investigated were: the heating rate, the reaction temperature, the salt to cyanamide ratio, the nitrogen content of the calcium cyanamide, moisture additions and calcium carbide additions. It was found that each of these variables had a significant effect on the product grade. The highest cyanide content of the product was obtained for salt to cyanamide mass ratios of 0.55 to 0.60. The salt reduces the decomposition rate of the cyanide and, therefore, at low salt to cyanamide ratios and at higher temperatures, the product grade is decreased. It is likely that the salt evaporates at the higher reaction temperatures and this decreases the cyanide capacity of the melt. High heating rates minimize the residence time and thus salt evaporation is reduced and higher grades can be obtained. As expected, the cyanide content increased with the nitrogen content of the cyanamide. Calcium carbide additions resulted in an increase in the product grade. The presence of small amounts of moisture in the charge caused a significant decrease in the cyanide content of the black cyanide. An equilibrium reaction is postulated in order to explain the black cyanide process and in particular the effect of calcium carbide on the product grade."

Jan 1, 2002